Gyroscopic air handler method and apparatus

ABSTRACT

A gyroscopic air handler provides a new powerful compact and efficient means to create airflow. At the core of the invention is a hubless magnetic chamber that rotates under its own power when acted upon by a composite electromagnetic duct. Composite field coils constructed from copper wire sheathed in a flexible iron sleeve are integrated into layers of Kevlar cloth and laid up with adhesive to create the desired shape as well as maintain the proper number of coils and spacing. Thrust bearings locate the hubless magnetic chamber within the duct. The invention can be retrofitted into the place of existing air handlers or purpose engineered for new applications. Gyroscopic inertia created by the magnetic chamber helps to dampen vibration as well as reduce the effects of unstable air conditions that can affect efficiency.

PRIORITY CLAIM

This application claims the benefit of US provisional patent application number 63/224,319, filed Jul. 21, 2021, the contents of which are incorporated by reference.

FIELD OF THE INVENTION

This invention relates to the field of air handlers. More specifically, the invention comprises a high flow air handler system which optionally replaces conventional air handlers used in everything from home air conditioners to mining ventilation. The invention creates a powerful, compact, and efficient system with the added benefits of gyroscopic inertia created by the rotating assembly, which helps to dampen errant vibrations and lessen the impact of incoming turbulent air.

BACKGROUND OF THE INVENTION

There are many known devices used for air handlers. Most of these use a standard AC motor connected to a large metal fan. One good example is an air handler used in a heat pump. Air from the air handler blows over evaporator coils circulating the heat energy into the refrigerant.

Air handler systems have been refined over time while still relying on industrial motors to rotate their pressed metal fans. The present invention provides a new, powerful, compact and efficient means to move air that creates inertia lessening pressure on bearings and related structures decreasing maintenance.

SUMMARY OF THE INVENTION

The present invention comprises a gyroscopic air handler for an air conditioning system. The invention is configured to be mounted/retrofitted in a similar position to existing air handlers, typically in the upper most section of evaporator coils/air filtration. Power is preferably provided through a breaker box/power panel.

The invention includes a hubless rotating magnetic chamber that houses rotors for air flow. The entire chamber is located by external thrust bearings that place the magnetic chamber within an electromagnetic duct. The duct itself creates electromagnetic energy in phases causing rotation of the magnetic chamber. The duct is created from a composite matrix that aligns iron sheathed magnetic wire in the desired location within its fabric. The fabric is laid up with an epoxy resin to take on almost any shape in the vertical plane. The magnetic chamber, when rotating, causes a strong vibration dampening gyroscopic effect while producing the desired air flow. A motor controller creates the phasing of the magnetic fields.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred and alternative examples of the present invention are described in detail below with reference to the following drawings:

FIG. 1 is a cross section view, showing the present invention.

FIG. 2 is a cross section view, showing the electromagnetic duct and the position of electromagnetic elements.

FIG. 3 is a cross section view, depicting a magnetic chamber with integrated permanent magnets and location of rotors.

FIG. 4 is a cross section view, of a thrust bearing assembly.

FIG. 5 is a top view, showing the layers of the composite structure of the electromagnetic duct section.

FIG. 6 is a top view of the duct and rotor.

FIG. 7 is a cross section view showing composite electromagnetic wire assembly.

FIG. 8 is a diagram showing a motor controllers connection to the electromagnetic wire assembly.

FIG. 9 is a cross section of an alternate embodiment of the current invention replacing the composite electromagnetic components with magnetic wire and iron stator stack.

REFERENCE NUMERALS IN THE DRAWINGS

-   -   10 electromagnetic duct     -   10 a inlet duct section     -   10 b composite electromagnetic duct section     -   10 c tail duct section     -   20 a composite electromagnetic wire assembly     -   20 b iron sheath     -   20 c copper wire with enamel coating     -   30 gyroscopic magnetic thrust chamber     -   40 permanent magnets     -   50 a upper rotor     -   50 b lower rotor     -   60 thrust bearings assembly     -   62 races or channels     -   70 bonding epoxies in void     -   80 composite electromagnetic wire locations     -   90 iron composite section     -   100 bonding epoxies in void     -   110 field coils     -   120 stator stacks

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising” when used in this specification, specify the presence of stated features, steps operations, elements, and/or components, but do not preclude the presence of addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which the invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the one context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

In describing the invention, it will be understood that a number of techniques and steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combination are entirely within the scope of the invention and the claims.

New gyroscopic air handler apparatuses are discussed herein. In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details.

The present disclosure is to be considered as an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated by the figures or description below.

The present invention is described by referencing the appended figures representing preferred embodiments. FIG. 1 shows a cross section view of the present invention. Gyroscopic air handler assembly 200 is shown with hubless magnetic thrust chamber 30 that creates air flow when rotated and a strong gyroscopic force that helps to dampen vibration harmonics of the assembly. A plurality of permanent magnets 40 are integrated into the exterior of a magnetic thrust chamber 30 that cause rotation of the chamber when acted upon by phasing magnetic fields created in one or more electromagnetic ducts. A plurality of hubless rotors 50 a upper and 50 b lower are attached to the inner diameter of the magnetic chamber 30. The design and number of rotors may be optimized for the desired results. The magnetic chamber 30 is supported by a plurality of thrust bearing assemblies 60 that allows free rotation.

FIG. 2 depicts the elements of an electromagnetic duct 10. The duct 10 surrounds the magnetic chamber 30 and is composed of three sections: 10 a inlet section that optimizes incoming airflow; 10 b composite electromagnetic section that integrates a plurality of composite field coils 20 a; and 10 c tail section that guides air into the desired location. The duct 10 may be composed of carbon fiber, Kevlar, aluminum or any appropriate material. A plurality of races or channels 62 accepts a plurality of thrust bearings to support the magnetic chamber, and are sized to accept the appropriate bearing for the desired application.

FIG. 3 shows a cross section of one design for a magnetic chamber 30 which may be made from lightweight composites, carbon fiber, aluminum or any material that will support the forces created by the chamber. A plurality of hubless rotors 50 a and 50 b are attached to the inside surface of the chamber. The rotor design, blade/screw is adapted to the desired air flow, size, and efficiency of the air handler. A plurality of permanent magnets 40 are attached to races 62 in the exterior of the chamber and attached with adhesive or any appropriate mechanical device.

FIG. 4 shows a cross section of an example of a thrust bearing assembly that may be used in the present invention.

FIG. 5 shows a cross section of the composite electromagnetic duct 10 b generally containing a ferrous structural element 10 a, a plurality of composite electromagnetic coils 80, ferrous magnetic focusing sections 90, and voids 70,80 that are filled with a nonferrous adhesive. The duct 10 c is to be constructed from Kevlar cloth or similar nonconductive material containing these elements that can be laid up as a composite with adhesive binder. The cloth are preferably laid up in such a manner that the electromagnetic composite coils are of the correct number and position to optimize the rotation of the magnetic chamber and its permanent magnets. Because of the composite nature of the duct, not only could the duct be made into almost any shape that is desired, but cooling is also greatly enhanced due to the airflow over its surfaces.

FIG. 6 depicts a top view of the assembly with 10 a inlet duct and 50 a hubless rotor. As shown with reference to FIG. 1 , the thrust bearings 60 are located so that they do not interfere with airflow.

FIG. 7 shows the makeup of the composite electromagnetic coils 20 a generally made from a copper core with enamel coating 20 c sheathed in a flexible ferrous layer containing iron particles within an adhesive 20 b. The length of each coil is configured to match the requirements necessary for efficient motor operation.

FIG. 8 shows a diagram of how the composite field coils 20 a are attached to a motor controller.

As shown with reference to FIG. 8 , when the composite coils 20 a are energized in phases through a motor controller, the electromagnetic fields act upon the permanent magnets in the magnetic chamber causing rotation. The number and orientation of the composite field coils are optimized to match the orientation and number of magnets in the magnetic chamber 30. This allows for design freedom in the shape of the duct in its vertical plane. The gyroscopic air handler is preferably positioned to optimize airflow for the desired use.

As shown with reference to FIG. 9 , an alternate embodiment of the invention 240 is described where the composite electromagnetic section 10 b of the duct is replaced with a more conventional iron stator stack and field coils in a housing that correctly orients the stator to the magnets in the magnetic chamber.

In an alternate embodiment the rotors 50 a,50 b, integrate a central hub and bearings that allow for the magnetic chamber to be supported from its center and a plurality of cross members integrated into the duct, to locate the hub assembly (not shown).

While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. 

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
 1. A gyroscopic air handler, comprising: a hubless magnetic chamber; a plurality of magnets affixed to a wall of the chamber; a plurality of hubless flywheels rotatably mounted to the wall of the chamber and configured to create air flow through the chamber when rotated; an electromagnetic duct having field coils integrated within its composite matrix; a plurality of thrust bearing that support the chamber within the electromagnetic duct; and a motor controller configured to send phased electrical energy to the electromagnetic cylinder to cause rotation of the magnetic chamber and hubless flywheels.
 2. The gyroscopic air handler of claim 1, wherein the composite matrix of the electromagnetic duct encapsulates field coils wherein the duct absorbs heat generated in the field coils.
 3. The gyroscopic air handler of claim 1, further comprising at least one thrust bearing that centers the magnetic chamber within the electromagnetic duct; and wherein the magnets affixed to the wall of the chamber are configured to create gyroscopic inertia when the chamber is rotated, reducing stress on the at least one thrust bearing that centers the magnetic chamber within the electromagnetic duct. 